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Looks like a broken knife tip or possibly wrong blade offset value

Looks like the corner nodes aren't properly connected.

The HPGL (Hewlett-Packard Graphics Language) has a fixed step size of 1016 steps/inch (0.025 mm) I think, while GPGL (Graphtec Plotter Graphics Language) has four options, 254 (0.1), 508 (0.05), 1016 (0.025) and 2540 (0.01). I believe 1016 is the GPGL default and it is fast and good enough for...

My guess is that the self test uses default step size (1016?) instead of the cutter driver setting, which may explain why the test cuts look perfect.

My first action would definitely be to change the step size. Long time since I used my old Graphtec cutter but I believe the GPGL default step size is 1016 (same as HPGL plotter language default), and 2032 should cut excellent details, although very slow. I'm not surprised at all if 254 steps...

No problem, mim. Please let us know the result.

My guess is, without knowing, that there shouldn't be more of a difference than between two batches of 1080 vinyl. And even if these vinyls are exactly the same, there may be visual differences depending on how long the first one has been exposed to weather and wear. So I agree with Geneva...

Explain the difficulties, risks and costs, and let your customer decide what to do.

FWIW, I tried the 'grid of 1" squares' method JBurton suggested and got 2,209 full squares inside the swoosh. I also got 709 squares that were along the border of the swoosh, and if we assume that these are around 50% of a full square on average, then we have to add 354.5 square inches to 2,209...

I started making some print samples with VJ-626UF when I first bought it three years ago, to see how colors would fade over time. These were put on a wall facing south, but I suspect my conditions here in southern Sweden can't be compared to Pennsylvania (should be more like Spain or Italy I...

Transparencies sounds like a plausible explanation, they can create some unwanted effects. Or is it possible that objects are set to Overprint perhaps? I remember some years ago, a client sent a PDF where white objects were set to Overprint and they disappeared completely (of course) when...

Normally you should not have to set the page size (roll width) in FineCut, it reads the pinch roller positions and set the size according to them. There is a "Default Sheet Size" setting in the Plotter/User setup dialog, but once the cutter has initialized and is set in "Remote" mode, FineCut...

I have had a CGFXII-160 for more than ten years and haven't had any problems using the entire width. Load the material, set pinch rollers in position, tell the cutter to read the position for two, three or all four rollers and it is ready to cut to that width. What program/plugin are you using...

I have to agree with WhiskeyDreamer, these tables are invaluable when you need an extra hand or two. Have had my RollsRoller table for more than ten years now and I couldn't do without it when applying vinyl and application tape, and it serves as an extra table for other work too. Sure, it was...

If the color management settings and profiles are the same in both Draw and Illustrator, and all export settings are too (sounds like you are printing via PDF), the result should also be almost identical from both. Draw X6 is old and Corel did a color management update many years ago, but I...

FWIW, I do not see any difference between a 100 K black and a 40, 40, 40, 100 black when printed on my HP 365. Guess the printer takes care of it and produces a good looking black. Why not make a test file, Ckapex, to see what looks best and if there is any difference at all?

Shouldn't happen. Would it be possible to post or upload the .CDR somewhere?

My experience with UV-ink on vinyl is limited to small stickers but I can tell you that if they are printed to the edges and put up outdoors, the ink will continue to harden over time and the edges will start to curl in a couple of months. I have seen stickers curl until they fell off because of...

I would print a sample from the PDF and show them what you get. Then be honest and tell them about the difficulties, and if they are not satisfied, take it from there. Maybe you could get an approved printed sample from them, so you know what they expect. Starting to adjust the file to get it...

CorelDRAW is a very good app Jim (as you already know), even though it has its bugs and beauty flaws, and there are few that can compete with it. And if you have so many .CDR files that you need to work on, the choice is simple. I still recommend to save all files in the format of your last...